Yarn carrier tube

ABSTRACT

A stackable dye tube for dyeing yarn has a first end, an opposing second end and a generally tubular lattice structure extending therebetween. An inner diameter and an outer diameter are defined by the tube body. The lattice structure comprises a plurality of rib portions and ring portions disposed generally perpendicular to the rib portions, each rib and ring portion being tapered from inside to outside. Projections extend outwardly from the lattice structure and have a projection length, extending away from the lattice structure, that is greater than a projection width that is measured in a direction perpendicular to the projection length.

FIELD OF THE INVENTION

The invention relates to the field of carrier tubes for dying of yarn.

BACKGROUND

In the textile industry, carrier tubes are utilized to support yarn during a dyeing process. The yarn is wound onto a carrier tube at high speeds to form a substantially cylindrical package of yarn on the tube. The yarn-supporting tubes are then supported on the spindle of a dye kettle for application of a dye medium. The tubes are commonly formed with mating ends to facilitate nested stacking of multiple yarn packages on one spindle. A dye medium is introduced into the dye kettle via the spindle for radial passage of the dye through the carrier tube and the supported yarn package. The carrier tubes are perforated to provide the necessary passageway for the dye from the spindle to the yarn. Known carrier tubes include tubes having intersecting elements which form a lattice type structure to provide the necessary perforations.

The prior art includes tubes made from metals such as stainless steel. However, metal tubes require thorough cleaning before reuse to prevent a previously applied dye medium from contaminating a dye medium subsequently applied. Known carrier tubes also include tubes made from plastic. Material and manufacturing cost efficiencies relating to molding of plastics facilitate the mass production of tubes for generally disposable use thereby eliminating the need to clean the tubes for re-use.

The perforations in the tube providing for passage of the dye medium should not excessively reduce the structural integrity of the tube. The perforated carrier tube must possess sufficient strength to carry loading applied to the tube. For example, the tubes typically incur an axial load after mounting on a spindle to seal the ends of the tube and to ensure that the dye medium will pass radially through the yarn rather than out of the ends of the tube.

Another factor to be considered is the thermal expansion of the tube and spindle. The dye medium used in the dyeing process is typically heated to a temperature that is slightly lower than the melting temperature of the plastic. This temperature results in a substantial softening of the plastic, making deformation under load relatively easy. Also, since the plastic material of the tube expands at a greater rate than the metal of the spindle, an additional axial load is created on the tube during the dyeing process. Considering this load and the relative softness of the plastic at the elevated temperatures, structural integrity of the tube may become compromised (at least to the extent of creating problems during unwinding of the dyed yarn).

The heat of the dye medium tends to shrink the yarn within the yarn package. The winding of the yarn on the tube creates a radially inward load around the circumference of the tube. To prevent damage to the yarn in response to compressive loads induced by the shrinkage of the yarn against the tube on which the yarn is wound, prior art tubes have incorporated flexible, or collapsible structures that provide for radial collapse.

Examples of radially compressible tubes are shown in U.S. Pat. No. 5,632,451 to Pasini and EP 0471353A to Zimmermann. Pasini discloses alternating transversely deformable longitudinal members and rigid longitudinal members. Stiffening tacks connect the alternating longitudinal members. Application of compressive hoop load to the tube, from shrinking yarn for example, causes deformation of the transversely deformable members and radial collapse of the tube as the rigid members adjacent the deformable members are directed towards one another. In Zimmermann, a lattice structure includes ring sections that do not intersect with each of the longitudinal members and are instead secured to some of the members by bowed elements. The bowed elements permit flexibility and radial compression of the carrier tube under compressive hoop loading.

SUMMARY OF THE INVENTION

The present invention relates to carrier tubes for the dying of yarn. As used herein, yarn includes any yarn, thread, or similar material that is typically used for weaving or knitting. One aspect of the invention comprises a dye tube having a hollow tubular body, including a first end, an opposing second end and a lattice structure extending therebetween. The tube body further defines an inner diameter and an outer diameter. The lattice structure comprises a plurality of rib portions and a plurality of ring portions, disposed generally perpendicular to the rib portions. Each of the rib and ring portions are tapered from inside to outside. Projections extend outwardly from the lattice structure and have a projection length that is greater than a projection width, measured in a direction perpendicular to the projection length.

A further aspect of the invention is a dye tube comprising a hollow, cylindrical, central body having opposing ends and a plurality of perforating openings for passage of a coloring dye therethrough. First and second end portions are respectively connected to opposite ends of the central body. Each of the first and second ends respectively include female and male elements at terminal ends thereof for nested engagement of adjacent tubes in a stack of aligned tubes. The central body has an inner diameter and an outer diameter, defined by a plurality of generally tapered longitudinal ribs and radial rings which define the plurality of perforating openings. At least one portion of each rib or ring has different angles of taper than another portion of the same rib or ring. The inner edges of the ribs and rings define the inner diameter of the body. The outer edges of each of the ribs and rings have at least one outwardly projecting protrusion that is approximately twice as tall as it is wide, which defines the outer diameter of the central body.

The first end portion has a substantially cylindrical female ring portion connected thereto. The female ring portion has an inner diameter that is larger than the inner diameter of the central body and an outer diameter defined by at least one outwardly protruding projection. The second end portion has a substantially cylindrical male ring portion connected thereto, which has an inner diameter that is equal to the inner diameter of the central body portion and an outer diameter that not substantially larger than the inner diameter of the female ring portion. The first and second ends are adapted to engage second and first ends of other generally identical dye tubes respectively to present a stacked arrangement of dye tubes having a substantially uniform inner diameter and an outer diameter defined entirely by outward projections extending from ribs and rings.

BRIEF DESCRIPTION OF THE DRAWINGS

For the purpose of illustrating the invention, there is shown in the drawings a form which is presently preferred; it being understood, that this invention is not limited to the precise arrangements and instrumentalities shown.

FIG. 1 is a perspective view of a dye tube according to an embodiment of the present invention.

FIG. 2 is a side elevational view of the dye tube of FIG. 1.

FIG. 3 is a cross-sectional view of the dye tube of FIG. 2.

FIG. 4 is a cross-sectional view of the dye tube of FIG. 1.

FIG. 5 is a cross-sectional view of mating end portions of dye tubes engaged with each other according to an embodiment of the present invention.

DETAILED DESCRIPTION OF THE DRAWINGS

In the figures, in which like reference numerals indicate like elements, there is shown an embodiment of a stackable dye tube according to the present invention, which is generally referred to by the numeral 10. The dye tube 10 provides for end-to-end stacking of multiple tubes, such as those mounted on the spindle of a dye kettle.

The dye tube 10 has a first end 12, a second end 14 and a tubular lattice structure 16 extending between the first end 12 and the second end 14. A longitudinal axis A extends through the center of the dye tube 10. The lattice structure 16 has an inner diameter D1 and an outer diameter D2. The lattice structure 16 defines a tubular longitudinal passageway 17 extending through the dye tube 10. The inner diameter D1 is sized to slidably receive the spindle of a dye kettle (not shown).

The first end 12 of the illustrated example of a dye tube 10 comprises a male fitting 18 having an inner wall 20 and an outer wall 22. The inner wall 20 defines a generally cylindrical opening having a diameter equal to that of the inner diameter D1 of the dye tube 10. The outer wall 22 has a diameter larger than the inner wall D1, thereby defining a thickness T1 of the male fitting 18. An outer tip 24 defines the terminus of the male fitting 18. A chamfer 25 may extend circumferentially around the male fitting 18 between the outer tip 24 and the outer wall 22. It is preferable that the inner wall 20 extends in a longitudinal direction, further away from the lattice structure than the outer wall 22. Although no radial passageways are shown extending through the portion of the dye tube 10 immediately adjacent to the male fitting 18, those skilled in the art will recognize that passageways may extend therethrough without departing from the scope of the present invention.

The second end 14 of the dye tube has a female fitting 26 with a proximal portion 28, located within the lattice structure 16, and a distal portion 30 located on an outer edge of the second end 14. The proximal portion 28 comprises an inner proximal wall 32 and an outer proximal wall 34. The inner proximal wall 32 defines a generally cylindrical passageway having a diameter that is substantially the same as the inner diameter D1 of the tube 10. The outer proximal wall 34 has a diameter that is substantially equal to the outer diameter D2 of the tube 10. The distal portion 30 has an inner distal wall 36 and an outer distal wall 38. The inner distal wall 36 has a diameter that in the illustrated example is slightly larger than the diameter of the outer wall 22 of the male fitting 18, but may alternatively have a diameter that is substantially equal to or slightly smaller than the diameter of the outer wall 22, depending on the type of fit that is desired between the outer wall 22 and inner distal wall 36. The outer distal wall 38 has a diameter that is substantially equal to the outer diameter D2 of the tube 10. A shelf 40 may define the distal terminus of the proximal portion 28 and the proximal terminus of the distal portion 30. When the male fitting 18 of a tube 10 is engaged with the female fitting 26 of a separate tube 10, it is preferable that the outer tip 24 of the male fitting 18 engages the shelf 40 of the female fitting 26. Those skilled in the art will recognize that although the outer proximal wall 34 is shown without radial passageways, that passageways may extend radially therethrough without departing from the scope of the present invention.

The illustrated example of a lattice structure 16 comprises a plurality of longitudinally extending ribs 42 and a plurality of longitudinally spaced circumferential rings 44. The lattice structure 16 is divided into two halves 45 and 47 which are disposed on opposite sides of plane P. The plane P longitudinally bisects the tube 10 and includes the longitudinal axis A. In the illustrated embodiment, a majority of the ribs 42 are disposed perpendicular to the plane P. The ribs 42 extend from the inside of the tube 10 towards the outside of the tube 10.

Each of the ribs 42 have an inner rib edge 48 that serve to partially define the longitudinal passageway 17. The inner rib edge 48 has a generally arcuate profile having a curvature equal to that of a circle with a diameter D1. The ribs 42 are generally tapered, having a wider cross-section at portions that are closer to the plane P than at portions that are further away from the plane P.

As best seen in FIG. 4, two T-shaped ribs 46 may be disposed on opposing sides of the tube 10. The T-shaped ribs 46 have lateral portions 46 a which extend along the plane P from the inside of the tube 10 towards the outside of the tube 10. A pair of perpendicular portions 46 b extend from opposing sides of the lateral portions of the T-shaped ribs 46. Like the ribs 42, the lateral portions 46 a have an inner edge 46 c with a generally arcuate profile that tracks the diameter D1. FIG. 4 also shows the ribs 42 extending away from the plane P with their widest points closest to the plane P. The ribs 42 have a generally elongated cross-sectional profile, extending away from the plane P, when viewed as in FIG. 4. The long thin profile of the ribs 42 provides for strength of the lattice structure, while maximizing the cross sectional area of the radial passageways 43 that extend between the ribs 42 and rings 44.

In the illustrated example, the plurality of lateral rings 44 extend generally perpendicular to the ribs 42, around the tube 10. The rings 44 have a circumferential inner ring wall 50, with a diameter D1. The inner ring wall 50 of each ring 44 defines the tubular passageway 17 (along with the inner rib edges 48 and the inner edge 46 c of the T-shaped ribs 46), and is therefore generally circular. The rings 44 extend radially away from the axis A. The ribs 42 and rings 44 define a plurality of passageways 43 that extend outwardly through the lattice structure 16.

The illustrated rings 44 are widest at portions closer to the axis A and decrease in cross-section at points away from the axis A. Some examples of the rings 44 have varying degrees of taper. In the illustrated example, an inner portion 54 has a generally gradual taper that extends radially outward from the inner edge 52. A beveled portion 56 is disposed on the ring 44 radially outward of the inner portion 54. The beveled portion 56 may have a steeper degree of taper than the inner portion 54. An outer portion 58 of each ring 44 is disposed radially outwardly of the beveled portion 56. The outer portion 58 has less of a taper than the beveled portion 56. Those skilled in the art will recognize that, although rings 44 are described here having a multi-angle taper, the ribs 42, or both the ribs 42 and rings 44 may have a multi-angle taper. There may be many varying degrees of taper, in addition to the embodiment disclosed here, without departing from the scope of the present invention. It is preferable that, regardless of the variation of taper and regardless of whether the rings 44, ribs 42 or both have such a taper, that the widest portion of the rib or ring is located at the portion thereof that is closest to the longitudinal axis A.

Outward projections 60 extend radially outward from each of the ribs 42 and the rings 44. The projections 60 extend along the radial outer edges of each of the ribs 42 and rings 44 and define the outer diameter D2 of the dye tube 10. The projections 60 have rounded edge 61 located at an outermost portion thereof. The rounded edge 61 is adapted to reduce damage to the yarn that are wound on the dye tube 10.

Each projection 60 has a projection length that is measured from the tip of the projection to the rib 42 or ring 44 from which it extends. The length is the distance that the projection extends away from the lattice structure 16. Each projection also has a projection width, measured in a direction that is perpendicular to the projection length. In some examples, the length of the projection 60 is greater than the projection's width. In other examples, the length of the projection 60 is twice the width.

The projections 60 are deformable in a manner that allows them to at least partially collapse towards the ribs 42 and rings 44 when an inward radial force is applied. The collapsing of the projections 60 occurs without comprising the structural integrity of the ribs 42 and rings 44. The inward radial force may be a result of the shrinking of the yarn wound on the dye tube 10 during the dying process. Deformation of the projections 60 allows for a reduction in the outer diameter D2 of the dye tube 10, thereby allowing a relaxation of the tension of the yarn wound on the dye tube 10 that occurs when the yarn shrinks.

It is preferable that the ribs 42 and rings 44 extend to the first and second ends 12, 14 of the dye tube. The ribs 42 and rings 44 are disposed around the entirety of the outer distal wall 38, thereby covering the exterior of the female fitting 26 of the dye tube 10. The illustrated ribs 42 extend longitudinally along the first end 18 until they terminate just before the male fitting 18. The rings are disposed about the sections that are covered by the ribs 42. The extension of the ribs 42 and rings 44 over the female fitting 26 and the first end 18 up to the male fitting 18 allow the entirety of the outer surface of a plurality of tubes that are stacked together to be covered with ribs 42 and rings 44, and therefore also with projections 58, as best shown in FIG. 5. In embodiments having this feature, the coverage of the entirety of the stacked dye tubes 10, provides for uniform relaxation of the tension on the yarn that are wound on the tubes 10.

The configuration of the ribs 42 and rings 44, with substantially parallel ribs extending away from the plane P, and a common inner diameter D1 of the lattice structure 16, allows the use of two outer mold portions in constructing the outer features of the dye tube 10. Because the components of the tube 10 share the same arcuate profile, defined by a circle having a diameter D1, a generally cylindrical inner mold having an outer diameter D1 is be used to define the inner portions of the tube 10. Each half of the dye tube 10 corresponds to a single outer mold portion, which may easily be withdrawn in the direction in which the ribs extend after solidification is complete. The use of only two outer molds and one inner mold, along with the ability to withdraw the outer mold portions substantially linearly, simplifies the manufacturing process.

In use, yarn is wound onto the dye tube 10 to facilitate handling of the yarn, during color treatment. Dye is applied to the yarn by causing the dye to flow through the tubular lattice structure 16 and through the wound yarn in a manner known to those skilled in the art.

A variety of modifications to the embodiments described will be apparent to those skilled in the art from the disclosure provided herein. Thus, the invention may be embodied in other specific forms without departing from the spirit or essential attributes thereof and, accordingly, reference should be made to the appended claims, rather than to the foregoing specification, as indicating the scope of the invention. 

1. A dye tube for dyeing yarn, the dye tube comprising: a hollow tubular body having a first end, an opposing second end, and a lattice structure extending between the first and second ends, the lattice structure defining inner and outer diameters of the dye tube, the lattice structure comprising a plurality of longitudinal ribs and a plurality of rings disposed generally perpendicular to the ribs, the ribs and rings being tapered from inside to outside, such that the portion of the ribs and rings adjacent the inner diameter is thicker than the portion of the ribs and rings adjacent the outer diameter; and the lattice structure further having projections extending outwardly from the ribs and rings, the projections having a projection length extending away from the lattice structure that is greater than a projection width that is measured in a direction perpendicular to the projection length.
 2. The dye tube of claim 1, wherein the projection length is at least double the projection width.
 3. The dye tube of claim 1, the first end being a female end comprising a generally cylindrical portion having an inner diameter larger than the inner diameter of the dye tube and an outer diameter that is substantially equal to the outer diameter of the dye tube and a plurality of ribs and rings disposed generally perpendicularly to the rib portions, each of the rib and ring portions extending outwardly from the first end to a circumferential terminus that is generally equal to the outer diameter of the lattice structure and being tapered from inside to outside and including at least one outer projection extending generally outwardly therefrom; and the second end further being a male end portion comprising a generally cylindrical end portion having an inner diameter that is generally the same as the inner diameter defined by the tubular lattice structure and an outer diameter that is structured to fit within the inner diameter of the female end portion.
 4. The dye tube of claim 1, wherein at least one of the ribs or rings has more than one angle of taper.
 5. The dye tube of claim 3, wherein at least one portion of the ribs or rings has a steeper taper than another portion of said ring or rib.
 6. The dye tube of claim 5, wherein the steeper taper portion of the ribs or rings is disposed between portions of the ribs or rings having less of a taper than the steeper portion.
 7. The dye tube of claim 1, wherein the second end portion is sized to be inserted into the first end portion during stacking.
 8. The dye tube of claim 1, wherein the first and second end portions are adapted to engage respectively second and first end portions of other generally identical dye tubes to present a stacked arrangement of dye tubes having a substantially uniform inner diameter and an outer diameter defined entirely by outer projections extending from ribs and rings
 9. A dye tube for dyeing yarn, the dye tube comprising: a hollow, generally cylindrical, body defined by a plurality of generally tapered longitudinal ribs and radial rings, the body having opposing ends and a plurality of perforating openings defined between the ribs and rings for passage of a coloring dye therethrough, the body defining an inner diameter and an outer diameter; the ribs and rings having an inside edge and an outside edge, at least one of the ribs or rings being tapered from inside to outside; the ribs and rings further having outwardly projecting protrusions, the protrusions having a length that is substantially parallel to the ribs and rings, and a width that is substantially perpendicular to the length, the length being greater than the width; and a first end portion having a substantially cylindrical female ring portion connected thereto, the female ring portion having an inner diameter that is larger than the inner diameter of the body and an outer diameter that is substantially equal to the outer diameter of the body, the lattice structure extending across the first end portion; a second end portion having a substantially cylindrical male ring portion, the male ring portion having an inner diameter that is substantially equal to the inner diameter of the body portion and an outer diameter that not substantially larger than the inner diameter of the female ring portion; and the first and second ends adapted to engage respectively second and first ends of other generally identical dye tubes to present a stacked arrangement of dye tubes having a substantially uniform inner diameter and an outer diameter defined entirely by outward projections extending from ribs and rings.
 10. The dye tube according to claim 9, where at least one portion of each rib has a different angle of taper than another portion of the same rib.
 11. The dye tube according to claim 9, where at least one portion of each ring has a different angle of taper than another portion of the same ring.
 12. The dye tube according to claim 9, wherein each of the ribs and rings have more than one outwardly projecting protrusion.
 13. The dye tube according to claim 9, wherein the length of the projections is at least twice the width of the projections.
 14. A dye tube for dyeing yarn, the dye tube comprising: a tubular body, having: a first end and a second end; a lattice structure extending between the first and second ends and defining inner and outer diameters of the dye tube, the lattice structure comprising a plurality of longitudinal ribs and a plurality of rings disposed generally perpendicular to the ribs; and projections extending outwardly from the lattice structure, the projections being structured to deform towards the ribs and rings in response to centripetal pressure resulting from contraction of a yarn wound around the dye tube.
 15. The dye tube according to claim 14, wherein the projections have a length in a direction outward from the lattice structure and a width substantially perpendicular to the length, the length being greater than the width.
 16. The dye tube according to claim 15, wherein the length of the projections is at least about double the length of the width of the projections.
 17. The dye tube according to claim 14, wherein: the tube defines an inner diameter and an outer diameter; the ribs and the rings are tapered from inside to outside, having an end adjacent to the inside diameter that has a width greater than a width of an end that is proximate to the outside diameter.
 18. The dye tube according to claim 17, wherein at least one portion of the rings or ribs has a steeper taper than another portion of the rings or ribs.
 19. The dye tube according to claim 14, wherein the first end is a female end and the second end is a male end structured to fit within a female end of an adjacent dye tube.
 20. The dye tube according to claim 19, wherein the lattice structure extends across the first end of the tube. 